U.S. patent number 4,743,517 [Application Number 07/090,303] was granted by the patent office on 1988-05-10 for fuel cell power plant with increased reactant pressures.
This patent grant is currently assigned to International Fuel Cells Corporation. Invention is credited to Richard F. Buswell, Ronald Cohen.
United States Patent |
4,743,517 |
Cohen , et al. |
May 10, 1988 |
Fuel cell power plant with increased reactant pressures
Abstract
The fuel cell power plant operates at higher reactant pressures,
and thus higher power density (lower cost) and efficiency, by
providing reactant reformer steam from a separate steam boiler.
Instead of supplying coolant steam to the reformer, the coolant is
operated in a closed loop apart from the reformer, and the coolant
steam is used to drive a steam generator to produce additional
electricity. A portion of the raw fuel is burned within the steam
boiler and the remainder is passed through the reformer and thence
to the fuel cells. Boiler exhaust is used to drive a turocompressor
which pressurizes the air used on the cathode side of the fuel
cells.
Inventors: |
Cohen; Ronald (West Hartford,
CT), Buswell; Richard F. (Glastonbury, CT) |
Assignee: |
International Fuel Cells
Corporation (South Windsor, CT)
|
Family
ID: |
22222196 |
Appl.
No.: |
07/090,303 |
Filed: |
August 27, 1987 |
Current U.S.
Class: |
429/425; 429/437;
429/442; 429/446; 429/456 |
Current CPC
Class: |
H01M
8/0612 (20130101); Y02E 60/50 (20130101) |
Current International
Class: |
H01M
8/06 (20060101); H01M 008/06 (); H01M 008/04 () |
Field of
Search: |
;429/17,20 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Walton; Donald L.
Attorney, Agent or Firm: Jones; William W.
Claims
We claim:
1. A fuel cell power plant system comprising:
(a) a power section comprising a plurality of fuel cells forming a
stack, each of said cells having an anode side and a cathode
side;
(b) means for cooling said stack with a water coolant, said means
for cooling including a water circulating loop and heat exchange
means in said stack through which the water coolant flows, said
water circulating loop including a steam separator for separating
coolant steam from a steam-water mixture exhausted from said heat
exchange means;
(c) a turbogenerator operated by steam from said steam separator
for generating a portion of the electrical power produced by said
power plant system;
(d) means for recirculating water from said steam separator back to
said heat exchange means in said stack;
(e) reformer means for catalytically converting raw hydrocarbon
fuel to a hydrogen rich fuel gas suitable for fueling the anode
side of the fuel cells;
(f) boiler means for producing steam having a temperature of at
least about 400.degree. F.;
(g) means for transporting steam from said boiler means at a
pressure greater than about 200 psi to said reformer means;
(h) means for admitting raw hydrocarbon fuel to said system, said
means for admitting including duct means for transporting the raw
hydrocarbon fuel to said reformer means for admixture with said
steam from said boiler means prior to entering said reformer
means;
(i) means for transferring hydrogen rich fuel gas from said
reformer means to said anode side of said fuel cells at a pressure
of at least about 200 psi; and
(j) means for supplying an oxidant gas at a pressure of at least
about 200 psi to said cathode side of said fuel cells.
2. The fuel cell power plant system of claim 1 wherein said means
for cooling said stack is operable to maintain said stack at an
operating temperature of about 400.degree. F.
3. The fuel cell power plant system of claim 1 wherein said fuel
cells operate at a pressure of about 400 psi; said steam from said
boiler means is at a pressure of about 450 psi; and said means for
cooling said stack operates at a pressure of about 135 psi.
4. The fuel cell power plant system of claim 1 wherein said boiler
means is fired with raw hydrocarbon fuel from said means for
admitting.
5. The fuel cell power plant system of claim 1 wherein said means
for supplying an oxidant gas comprises a turbocompressor operated
by exhaust from said boiler means.
6. The fuel cell power plant system of claim 1 further comprising
condenser means operable to condense water out of the exhaust from
said turbogenerator, and means operable to return the condensed
water from said condenser means to said means for recirculating
water.
7. A fuel cell power plant system comprising:
(a) a power section comprising a plurality of fuel cells forming a
stack, each of said cells having an anode side and a cathode
side;
(b) means for cooling said stack to an operating temperature of
about 400.degree. F. with a water coolant, said means for cooling
operating at an internal pressure of about 135 psi and including a
water circulating loop comprising heat exchange means in said stack
through which the water coolant flows, said water circulating loop
also including a steam separator for separating coolant steam from
a steam-water mixture exhausted from said heat exchange means, and
means for recirculating water from said steam separator back to
said heat exchange means;
(c) means for supplying an oxidant gas at pressures of about 400
psi to said cathode side of said cells;
(d) reformer means for catalytically converting raw hydrocarbon
fuel to a hydrogen rich fuel gas suitable for fueling the anode
side of the fuel cells;
(e) means for supplying a raw hydrocarbon fuel to said reformer
means at pressures of about 400 psi;
(f) boiler means for producing steam at pressures of about 450
psi;
(g) means for delivering high pressure steam from said boiler means
to said reformer means for admixing with said raw hydrocarbon fuel
before entering said reformer means, said high pressure steam and
said raw hydrocarbon fuel providing a mixture which is
catalytically converted in said reformer means to a hydrogen rich
fuel at a pressure of about 400 psi; and
(h) means for delivering said hydrogen rich fuel from said reformer
means to said anode side of said fuel cells at a pressure of about
400 psi.
8. The fuel cell power plant system of claim 7 further comprising a
turbogenerator operated by steam from said steam separator; and
condenser means for condensing water out of exhaust from said
turbogenerator, said condenser means being operably connected to
said means for recirculating water whereby the condensed water is
recirculated back to said heat exchange means.
9. The fuel cell power plant system of claim 7 wherein said boiler
means is fired with raw hydrocarbon fuel from said means for
supplying raw hydrocarbon fuel.
10. The fuel cell power plant system of claim 9 further comprising
a turbocompressor means for compressing said oxidant gas, said
turbocompressor means being run by exhaust from said boiler
means.
11. A method of operating a fuel cell power plant, said method
comprising the steps of:
(a) providing an oxidant gas at pressure of at least 200 psi to an
oxidizing portion of said fuel cell power plant;
(b) providing a supply of raw hydrocarbon fuel pressurized to a
pressure of at least 200 psi;
(c) providing a supply of steam which is pressurized to a pressure
greater than that of said raw hydrocarbon fuel;
(d) mixing said raw hydrocarbon fuel and steam;
(e) catalytically converting said fuel and steam mixture into a
hydrogen rich fuel;
(f) providing said hydrogen rich fuel at a pressure of at least 200
psi to a reducing portion of said fuel cell power plant; and
(g) cooling said fuel cell power plant with a closed loop water
coolant system operating at an internal pressure of less than 200
psi which loop is completely isolated from said raw hydrocarbon
fuel and said hydrogen rich fuel.
12. A method of operating an acid fuel cell power plant, said
method comprising the steps of:
(a) providing air at a pressure of about 400 psi to a cathode
portion of said fuel cell power plant;
(b) providing a supply of raw hydrocarbon fuel pressurized to a
pressure of about 400 psi;
(c) providing a supply of steam which is pressurized to a pressure
greater than about 400 psi;
(d) mixing said raw hydrocarbon fuel and steam;
(e) catalytically converting said fuel and steam mixture into a
hydrogen rich fuel;
(f) providing said hydrogen rich fuel at a pressure of about 400
psi to an anode portion of said fuel cell power plant; and
(g) cooling said fuel cell power plant to an operating temperature
of about 400.degree. F. with a closed loop water coolant system
operating at an internal pressure of about 135 psi, said closed
loop being completely isolated from said raw hydrocarbon fuel and
said hydrogen rich fuel.
13. The method of claim 12 including the step of separating steam
from water in said closed loop, and using the separated steam to
drive an electric turbogenerator to produce additional electrical
output.
14. The method of claim 12 wherein said steam is supplied by
boiling water in a boiler fired by a portion of said raw
hydrocarbon fuel.
15. The method of claim 14 wherein said air is pressurized by a
compresssor operated by exhaust from said boiler.
Description
DESCRIPTION
1. Technical Field
This invention relates to pressurized fuel cell power plants, and
more particularly, to acid fuel cell power plants which are
operated at higher than normal reactant pressures without unduly
elevating the operating temperatures of the cells.
2. Background Art
As a general rule, acid type fuel cell power systems will operate
more efficiently and with increased power density (lower cost) in a
pressurized environment. Elevated steam pressures are generated in
the fuel cell stacks of the system by heating water to elevated
temperatures in the cooling system. The steam pressure will thus be
proportional to the cell stack temperature. In an acid fuel cell
system, the elevated pressure on the cathode or oxygen side of the
system will be created by compressing air fed into the system by
means of a turbocompressor which is operated with waste heat from
the power plant. On the fuel side, raw hydrocarbon fuel will be
elevated in pressure by an electrically driven pump or compressor
and fed into a catalytic reformer vessel where the fuel is mixed
with the heated steam at an elevated pressure. The raw fuel is thus
catalytically converted to a hydrogen enriched fuel gas suitable
for use in the electrochemical reaction in the fuel cells. This
enriched fuel is fed to the anode side of the fuel cell power
section of the plant from the reformer. This catalytic reforming of
the fuel gas and the electrochemical reactions in the fuel cells
proceed more vigorously at higher pressures and temperatures. In
order to ensure proper fluid flow in the system, the reactant
pressures cannot be higher than the steam pressure.
In the prior art, the steam for the reformer has typically been
provided by routing steam from the coolant, after the latter has
cooled the cells, to the reformer. Such a system is shown in U.S.
Pat. No. 3,982,962 Bloomfield, granted Sept. 28, 1976. When coolant
steam is used in the reformer, the temperature and pressure of the
steam in the reformer are limited by the operating temperatures of
the cells in the power section which are being cooled by the
coolant. In acid fuel cells, and particularly in phosphoric acid
fuel cells, the material from which the cell components are made
impose a maximum permissible operating temperature on the cells of
about 450.degree. F. If the operating temperatures of the cells
exceed the maximum permissible operating temperatures, the cells
will begin to fail. Acid fuel cell stacks are cooled by coolant
passages which are interspersed throughout the stacks and which
carry a coolant fluid, typically water. The coolant passages are
preferably pipes which traverse the cell stack. These coolant pipes
will typically be spaced apart in the stack so that each coolant
pipe level will serve to cool about four or so cells on each side
(above and below) the coolant pipe levels. A coolant system of this
general type is disclosed in U.S. Pat. No. 4,574,112, Breault et
al., granted Mar. 4, 1986. With this type of coolant system it will
be appreciated that the coolant temperature will not reach the
level of the temperature of the cells because the cooling is not
performed one-on-one with the cells. For example, if one were to
desire to operate the fuel gas reformer at a pressure of 450 psi to
feed hydrogen-rich gas to fuel cell stacks operating at about 400
psi, the pressure in the coolant tubes in the power section of the
stack would have to be greater than 450 psi. In order to produce
this 450 psi coolant pressure, the temperature of the coolant steam
would have to be greater than 460.degree. F. in the coolant tubes.
To achieve this 460.degree. F. steam temperature in the coolant
tubes, the cells would have to operate at temperatures greater than
500.degree. F., which is above the maximum permissible extended
operating cell temperature. It is thus apparent with the cooling
and steam reforming systems of the prior art, one must not operate
the fuel gas reformer at pressures in excess of about 175 psi, and
that this pressure limit is the direct result of the maximum
permissible power section fuel cell operating temperatures. This
also places an upper limit of less than 175 psi on the operating
pressure in the cells.
DISCLOSURE OF INVENTION
As previously noted, it is highly desirable to elevate the
operating pressure of the fuel gas reformer and fuel cells to
improve efficiency and power density. We have invented a fuel cell
power plant system which can operate with an acid electrolyte,
particularly phosphoric acid, wherein the fuel gas reformer and
fuel cells can be operated at pressures in excess of 200 psi and as
high as about 400 psi while the cell operating temperatures are
maintained at safe levels of about 400.degree. F. The benefits of
our system include smaller, more efficient, less expensive
reformers, fuel cells, heat exchangers, piping and controls, along
with longer cell life. The power output of the system of our
invention is equivalent to the prior art system per unit of
operating fuel consumed, but the equipment size is smaller,
improving cost per kilowatt of electricity produced.
In the system of this invention, the fuel cell power section is
cooled by water recirculated in a closed loop which loop does not
extend to the reformer in the system. The two phase water-steam
mixture produced by cooling the power section with water is cycled
to a steam separator where the steam fraction is separated from the
water fraction. The water fraction is returned to the cooling
passages in the power section. The separated steam fraction is fed
to a steam turbine generator which is operated by the coolant steam
to generate electricity. About 20% of the electricity generated by
the system thus is derived from the coolant steam. The exhaust from
the steam turbine passes through a condenser whereupon the water
condensate is fed into the water recycled from the steam separator
to the coolant passages. Steam for operating the reformer is
produced by a boiler into which water is fed and boiled to produce
steam. The boiler is fired partly by a fraction of the raw
hydrocarbon fuel which is used to operate the fuel cells. Steam is
produced by the boiler at a temperature of about 460.degree. F. and
is fed to the reformer which is operating at a pressure of about
450 psi. The raw hydrocarbon fuel not used to fire the boiler is
fed into the reformer for conversion to a hydrogen-enriched fuel
suitable for fueling the fuel cells. The reformer is heated by
burning anode and cathode exhaust gases in a burner associated with
the reformer to maintain the reformer operating temperature. The
exhaust from the reformer burner is fed to the boiler to help fuel
the latter along with the raw fuel diverted for that purpose. The
burner exhaust from the steam boiler is used to drive a
turbocompressor which compresses the air fed to the cathode side of
the power section of the system.
It is therefore an object of this invention to provide a fuel cell
power plant which can be operated at high reactant pressures for
improved cost, size and efficiency.
It is a further object of this invention to provide a power plant
of the character described which utilizes an acid electrolyte and
wherein the cells can be operated at optimum temperatures.
It is another object of this invention to provide a power plant of
the character described wherein reformer steam used to generate the
reactant at higher pressures is produced by a steam boiler fired at
least partially by raw fuel.
It is an additional object of this invention to provide a power
plant of the character described wherein the power section is
cooled by a recycling water coolant loop with coolant steam being
used to drive a steam powered electricity generator.
It is yet another object of this invention to provide a power plant
of the character described wherein the reformer steam system and
the coolant steam system are completely separate from each other
and operate independently of each other.
These and other objects and advantages of the invention will become
more readily apparent from the following detailed description of a
preferred embodiment thereof when taken in conjunction with the
accompanying drawing .
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a schematic representation of a power plant
configured in accordance with the invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring to the drawing, the electrochemical power section of the
plant is denoted generally by the numeral 2, and includes an anode
side 4, a cathode side 6 and a cooling portion 8. It will be
appreciated that the power section 2 is actually a stack of
rectangular fuel cells disposed one atop the other, with the anode
side 4 being fueled with hydrogen rich fuel via a first manifold on
one side of the stack with the anode exhaust gas being removed via
a second manifold on the side of the stack opposite the first
manifold. The cathode side is fed oxygen (air) in a direction
transverse to the hydrogen gas flow via manifolds on the remaining
two sides of the stack. Coolant water is admitted to the power
section cooling portion 8 via inlet line 10 and the two-phase
water-steam mixture formed as a result of the cooling operation
leaves the cooling portion 8 through outlet line 12. The
water-steam mixture is fed into a steam separator drum 14 wherein
the water phase is separated from the steam phase. The water phase
is returned to the inlet line 10 through line 15 by means of a pump
16. The steam phase leaves the separator 14 through a line 18 and
is used to drive a turbine 20 which in turn operates a generator 22
to produce electricity. Exhaust from the turbine 20 passes to a
condenser 24 through a line 26, and water condensed out of the
turbine exhaust is returned to the coolant inlet 10 through lines
28 and 15. The temperature of the water in the line 10 is about
350.degree. F., the temperature of the water-steam mixture in the
line 12 is about 350.degree. F., and the temperature of the steam
in the line 18 is about 350.degree. F. At these temperatures, the
pressure in the cooling portion 8 is about 135 psi and the cells in
the power section 2 will be operating at a maximum temperature of
about 400.degree. F. Air for the cathode side 6 enters the system
through line 30 where it is compressed to a pressure of about 400
psi by compressor 32 and fed to the cathode side 6 through cathode
inlet line 34. Raw hydrocarbon fuel which has been compressed to a
pressure of about 400 psi by a pump 35 enters the system via line
36 where a control valve 38 diverts about 20% of the raw fuel into
line 40 to be burned to fire a boiler 42 which produces high
temperature, high pressure steam. Water from line 44 passes through
the boiler 42 where it is converted to steam which is transported
to a catalytic hydrocarbon fuel reformer 46 through line 48 and
mixed with the raw hydrocarbon fuel in line 50 at the reformer
inlet. The remaining 80% of the raw hydrocarbon fuel also is
transported to the reformer 46 via line 50 from the valve 38. The
steam in the line 48 and reformer 46 will be at a pressure of about
450 psi and a temperature of about 460.degree. F. The reformed
hydrogen-rich fuel gas moves from the reformer 46 through an outlet
line 52 to the inlet side of the anode 4. Exhaust from the anode
side 4 is emitted to an outlet line 54 whereby it is transported to
a burner 56 associated with the reformer 46. Exhaust from the
cathode side 6 is transported to the reformer burner 56 by means of
cathode outlet line. The anode and cathode exhausts which contain
hydrogen and oxygen are burned in the burner 56 to maintain the
reformer operating temperature at about 1800.degree. F. Exhaust
from the burner 56 still containing some oxygen is transported to
the boiler 42 by line 60 for admixture with the raw fuel from line
40 and burned. Exhaust from the boiler 42 is fed to a turbine 62
through line 64, the turbine 62 being operable to drive the air
compressor 32.
It will be noted from the aforesaid description that the reformer,
which is a conventional steam reformer, operates entirely
independently of the power section coolant system. This invention
thus enables one to operate the cell stack power section and
coolant system at optimum pressures above 200 psi, and preferably
at about 400 psi but with low temperatures of about 400.degree. F.
which will ensure longer component and electrolyte life for the
power plant. At the same time, the reformer can be operated at
optimum pressures of about 450 psi and temperatures of about
1800.degree. F. so as to ensure optimum reforming of the fuel gas
and extended catalyst life. These optimum conditions can be
realized even though they would be mutually exclusive with the
systems of the prior art which use coolant steam for the reforming
process. Since a portion of the raw fuel is used to fuel the steam
boiler, not all of the fuel consumed by the system will be used in
the electrochemical production of electricity, thus the system will
produce less electrochemical electricity per unit of fuel consumed
than a prior art stack, however, the use of the coolant steam to
drive the steam turbine electric generator provides additional
electricity not electrochemically produced because of the fuel
diversion. The total electrical power produced by the plant is thus
equivalent per unit of fuel consumed, to that produced by a prior
art conventional stack. A power system which embodies this
invention can be made smaller and less expensively because
increasing the system pressure improves cell performance and allows
a reduction in the size of the fuel cells, fuel processing and
thermal management reactors, piping and heat exchangers.
An example of improved performance with increasing pressure is the
behavior of the fuel cell. In current pressurized systems, cell
stacks operate at 120 psi. That is, the air on the cathodes and the
hydrogen rich fuel gas on the anodes are at 120 psi. The water in
the cooling tubes is at about 160 psi and 365.degree. F. The cells
operate at 200 amps per square foot (ASF) and a voltage of 0.75
volts. Therefore, each cell generates about 150 watts per square
foot (WSF). Using the format of this invention, the system could
operate with the reactant gases at 400 psi and the cells would
generate a voltage of 0.82 volts at 200 ASF. This means the
efficiency of the cells would be higher by 7 percentage points and
the power density would be increased to 164 WSF. If only higher
power density were desired, the cells could be operated at the same
voltage (0.75 volts) but at much higher current density of 500 ASF.
This would increase the power density to 375 WSF. If desired, an
intermediate current density, between 200 ASF and 500 ASF could be
picked as the operating point and a combination of higher
efficiency and higher power densiity would result. As can be seen
by these examples, significant improvements result with higher
pressure operation made possible by this invention.
Since many changes and variations of the disclosed embodiment of
the invention may be made without departing from the inventive
concept, it is not intended to limit the invention otherwise than
as required by the appended claims.
* * * * *